Conair Thermolator TW-P User Manual Download

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Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

U S E R G U I D E
UGH056-0917

Thermolator

TW-S and TW-P

Temperature Control Units

TW-S

TW-P

Summary of Contents for Thermolator TW-P

Page 1: ...up com Corporate Office 724 584 5500 l Instant Access 24 7 Parts and Service 800 458 1960 l Parts and Service 814 437 6861 U S E R G U I D E UGH056 0917 Thermolator TW S and TW P Temperature Control Units TW S TW P ...

Page 2: ...e Manual Number UGH056 0917 Serial Number s Model Number s DISCLAIMER Conair shall not be liable for errors contained in this User Guide or for incidental consequential damages in connection with the furnishing performance or use of this information Conair makes no warranty of any kind with regard to this information including but not limited to the implied warranties of merchantability and fitnes...

Page 3: ...t Injection Works 2 3 How the Closed Circuit Works 2 4 How the Closed Circuit Separate Source Works 2 5 TW P Control Features vs TW V and TW S 2 6 Specifications TW P 2 7 TW P Features and Options 2 8 Options 2 8 3 1 I n s t a l l a t i o n Unpacking the Boxes 3 2 Preparing for Installation 3 3 Connecting Process and Water Supply Lines Without Purge 3 4 Mold Purge Valve Connections 3 5 Connecting ...

Page 4: ...ing the Pump Motor and Seal 1 2 to 3 Hp units 5 7 Removing the Pump Motor and Seal 5 to 10 Hp units 5 9 Reassembling Pump Motor and Seal 5 to 10 Hp units 5 11 6 1 Tr o u b l e s h o o t i n g Before Beginning 6 2 A Few Words of Caution 6 3 Identifying the Cause of a Problem 6 4 Controller Alarms 6 5 Controller Control Fault Logic 6 14 Unit Faults 6 15 Unit Will Not Power Up 6 26 Troubleshooting 6 ...

Page 5: ... e n d i x PID Parameters B 1 Setting the Security Passcode B 4 C A p p e n d i x Plumbing Diagram C 1 Plumbing Curves C 4 D A p p e n d i x Service Parts D 1 E A p p e n d i x External Interfaces E 1 F A p p e n d i x Pressure Switch Settings F 1 G A p p e n d i x Mold Purge Installation Instructions G 1 H A p p e n d i x Flowmeter Installation Instructions H 1 ...

Page 6: ...iv I Table of Contents ...

Page 7: ...ucti o n Introduction I 1 1 Introduction Purpose of the User Guide 1 2 How the Guide Is Organized 1 2 Your Responsibilities as a User 1 2 Foreword 1 3 ATTENTION Read This So No One Gets Hurt 1 4 How to Use the Lockout Device 1 5 ...

Page 8: ...s indicate tasks or steps to be performed by the user A diamond indicates the equipment s response to an action performed by the user or a situation An open box marks items in a checklist A circle marks items in a list Indicates a tip A tip is used to provide you with a suggestion that will help you with the maintenance and the operation of this equipment Indicates a note A note is used to provide...

Page 9: ...request We strive to maintain an accurate record of all equipment during the course of its useful life Due to the ever changing nature of applicable codes ordinances and other local laws pertaining to the use and operation of this equipment we do not reference them in this manual There is no substitute for common sense and good operating practices when plac ing any mechanical equipment into operat...

Page 10: ...t is powered by three phase alternating current as specified on the machine serial tag and data plate A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure Improp er grounding can result in severe personal injury and erratic machine operation Always disconnect and lock out the incoming main power sour...

Page 11: ...n removed and all safety guards reinstalled Lockout is the preferred method of isolating machines or equipment from energy sources Your Conair product may be equipped with the lockout device pictured below To use the lockout device 1 Stop or turn off the equipment 2 Isolate the equipment from the electric power 3 Turn the rotary disconnect switch to the OFF or O position 4 Secure the device with a...

Page 12: ...1 6 I Introduction ...

Page 13: ...ations 2 2 How the TW S and TW P Series Direct Injection Works 2 3 How the Closed Circuit Works 2 4 How the Closed Circuit Separate Source Works 2 5 How the TW P Direct Injection Works 2 5 TW S Control Features vs TW V and TW P 2 6 TW P Control Features vs TW V and TW S 2 7 Specifications TW S 2 8 Specifications TW P 2 9 ...

Page 14: ...y from the water supply DI models are designed for Process temperatures up to 250 F 121 C with options up to 300 F 149 C Use with chiller water or properly treated and filtered tower or city water Direct injection models may be used with glycol water process loop mixtures as long as the glycol does not exceed 50 of the mixture If your application requires a higher percentage of glycol or if you ha...

Page 15: ...h the To Process line A to the mold or process The fluid returns to the unit through the From Process line B for reheating or cooling 2 The temperature of the process fluid is measured as it flows into the mixing tank through the From Process line B 3 If the To Process temperature is above the setpoint value the cooling valve opens Cool water enters the bottom of the mixing tank via the Cooling In...

Page 16: ...ine A to the mold or process The fluid returns to the unit through the From Process line B for reheating or cooling 2 If the temperature is above the setpoint value the cool ing valve opens Cool water enters the heat exchanger via the Cooling In line Process fluid is always being circulated through the process side of the heat exchanger The process fluid is indirectly cooled via conduction from th...

Page 17: ...to the unit through the From Process line B for reheating or cooling 2 Alternatively the temperature of the process fluid may be measured as it flows into the mixing tank through the From Process line B 3 If the temperature is above the setpoint value the cooling valve opens Cool water enters the heat exchanger via the Cooling In line Process fluid is always being circu lated through the process s...

Page 18: ...W V Direct Injection Closed Circuit Common Source Closed Circuit Separate Source Construction Standard Pump Range 3 4 to 10 Hp 0 56 to 7 45 KW 3 4 to 10 Hp 0 56 to 7 45 KW Standard Heater Range 0 to 48 KW 12 KW Cast Heater Pump Incoloy Heaters Silicon Carbide Seals Pressure Gauges 250 F Setpoint Range 300 F Setpoint Range Controls PID Control Setpoint Actual Display Password Protection Modbus RTU ...

Page 19: ...r Range 0 to 48 KW 12 KW Cast Heater Pump Incoloy Heaters Silicon Carbide Seals Pressure Gauges 250 F Setpoint Range 300 F Setpoint Range Controls PID Control Setpoint Actual Display Password Protection Modbus RTU via RS 485 SPI via RS 485 Retransmit Process Temp 4 20mA Hand Held Remote Auto Restart Capability High Temperature Safety Mold Purge Phase Detection Circuit Heat Error for Heater Malfunc...

Page 20: ...25 9 15 0 12 9 10 5 33 4 19 3 16 7 13 5 48 5 28 0 24 2 19 5 1 0 Hp 0 75 kW 26 8 15 2 15 3 13 3 10 6 34 3 19 5 19 6 17 1 13 6 49 4 28 2 28 3 24 5 19 6 2 0 Hp 1 49 kW 28 9 16 6 16 7 14 3 11 6 36 4 20 9 21 0 18 1 14 6 51 5 29 6 29 7 25 6 20 6 3 0 Hp 2 24 kW 31 7 13 4 18 0 15 4 12 5 39 2 22 4 22 3 19 2 15 5 54 3 31 1 31 0 26 7 21 5 5 0 Hp 3 73 kW 36 3 20 7 18 2 17 7 14 2 43 8 25 0 22 5 21 5 17 2 58 9 ...

Page 21: ...9 15 0 12 9 10 5 33 4 19 3 16 7 13 5 48 5 28 0 24 2 19 5 1 0 Hp 0 75 kW 26 8 15 2 15 3 13 3 10 6 34 3 19 5 19 6 17 1 13 6 49 4 28 2 28 3 24 5 19 6 2 0 Hp 1 49 kW 28 9 16 6 16 7 14 3 11 6 36 4 20 9 21 0 18 1 14 6 51 5 29 6 29 7 25 6 20 6 3 0 Hp 2 24 kW 31 7 13 4 18 0 15 4 12 5 39 2 22 4 22 3 19 2 15 5 54 3 31 1 31 0 26 7 21 5 5 0 Hp 3 73 kW 36 3 20 7 18 2 17 7 14 2 43 8 25 0 22 5 21 5 17 2 58 9 33 ...

Page 22: ...from molds and hoses Alarm packages The Thermolator control includes an output relay that can be connected to an optional external alarm package to call attention to alarm conditions Stacking Rack Save floor space by stacking Thermolators two high The stacking rack can be used only with single zone models with a height of less than 30 inches 262 mm high cabinets Incoloy heaters minimize chemical a...

Page 23: ...n 3 3 Rigging 3 4 Fluid Distribution Piping 3 4 Installation Electrical 3 5 Connecting Process and Water Supply Lines without Purge 3 6 Optional Mold Purge Valve Connections 3 7 Connecting the Main Power Source 3 8 Testing the Installation 3 9 Initial Setup 3 10 Temperature Units 3 11 Setpoint 3 12 Alarm Points 3 13 ...

Page 24: ...amage occurred during shipping Check all wire terminal connections bolts and any other electrical connections which may have come loose during shipping 4 Record serial numbers and specifications in the blanks provided on the back of the User Guide s title page This information will be helpful if you ever need service or parts 5 You are now ready to begin installation See Installation Section entit...

Page 25: ...ell ventilated environment The room temperature should not exceed 104 F 40 C with 95 non condensing humidity and should not fall below 32 F 0 C U U Minimum clearance for safe operation and maintenance The diagram at the right shows minimum clearance for operation You also need enough clearance in rear for water hookups For maintenance you should move the Thermolator to provide at least 36 inches 9...

Page 26: ...d adds a substantial heat load and becomes an additional burden for the cooling system The importance of properly sized piping between the cooling system and the temperature control unit and between the temperature control unit and the process cannot be over emphasized See the ASHRAE Handbook or other suitable design guide for proper pipe sizing In general run full size piping out to the process a...

Page 27: ... V3 3 Vx phase with greatest difference from Vavg For example if the three measured voltages were 442 460 and 454 volts the average would be 442 460 454 3 452 The percentage of imbalance is then 452 442 x 100 452 2 2 This exceeds the maximum allowable of 2 There is a terminal block for main power connection to the main power source The main power source should be connected to the terminal block th...

Page 28: ...nt removing all oil grease and dirt Allow the threads to dry before proceeding 3 Coat the pipe threads with thread sealant Follow the sealant manufacturer s directions 4 Connect the male pipe to the appropriate female connection on the back of the unit Start by hand until the threads engage then use a pipe wrench to tighten the connection only enough to prevent leaks Do not over tighten Tools for ...

Page 29: ...pipe threads must be clean and new Clean threads with solvent removing all oil grease and dirt Allow the threads to dry before proceeding 4 Coat the pipe threads with thread sealant Follow the sealant manufacturer s directions 5 Connect the male pipe to the appropriate female connection on the back of the unit Connect cooling water lines as indicated on the previous page Connect process lines as i...

Page 30: ... specified on the machine serial tag and data plate 1 Open the unit s electrical enclosure Removing the top panel is recommended The Thermolator comes from the factory with a knockout for 1 2 inch conduit A knockout punch should be used if necessary to enlarge the hole for larger diameter conduits 2 Insert the main power wires through the conduit in the right side of the enclosure See electrical p...

Page 31: ... button and look at the pump shaft With a flashlight verify that the pump rotation matches the direction indicated on the rotation sticker on the side of the pump motor NOTE If the rotation is incorrect stop the test and disconnect power to the unit Open the electrical enclosure and switch any two of the three power source wires on the incoming power distribution block Return to step 2 and check r...

Page 32: ...the factory set parameters see Default Parameters in the appendix of this user guide All parameters can be changed using the keypad and the menu system Continued Mold Purge Rapid Cool Process Cool Down Control Power Autostart Signal Pump Heat Cool Coolant Pressure Temperature Limit Electrical Phase Error Heat Error Process Cool Down Rapid Cool Communications Remote Heat Cool Program Mode Mold Purg...

Page 33: ...ion button for 5 seconds If the passcode is at its default 0 simply push Select If the passcode has been changed to something else use the Up and Down buttons to scroll to the correct passcode and then push Select 3 Repeatedly push Select to scroll through available user parameters until Unt Units is displayed in the upper display about 2 presses In the lower display use the Up or Down buttons to ...

Page 34: ...ill automatically be implemented a few seconds after the up or down button is released NOTE From the factory the TW P will control the To Process or Supply fluid to the setpoint Mold Purge Rapid Cool Process Cool Down Control Power Autostart Signal Pump Heat Cool Coolant Pressure Temperature Limit Electrical Phase Error Heat Error Process Cool Down Rapid Cool Communications Remote Heat Cool Progra...

Page 35: ...w deviation alarm limit to degrees below setpoint h High deviation alarm limit to degrees above setpoint Deviation delays below modify the deviation alarms above You can select how long you want the system to tolerate a temperature excursion outside of the deviation window before alarming Machine startup ignore deviation delay to minutes Alarm delay for low deviation to minutes to minutes on progr...

Page 36: ...3 14 I ...

Page 37: ...t Display 4 6 Starting the Thermolator 4 7 Stopping the Thermolator 4 13 Program Menu 4 14 Program Menu Items 4 15 Process Cool Down Sequence Initiation 4 16 Pump Running Hour Display 4 16 SPI Communications Optional 4 16 SPI Option Parameters 4 17 Modbus RTU Optional 4 18 Modbus Option Parameters 4 18 Modbus Registers 4 19 Using the Mold Purge Option 4 19 Conair TW P Thermolator 4 20 ...

Page 38: ...hold the button during entire unit cycle Stop Pump Button Press to stop the Thermolator Push again to de assert and allow restart Status Lights The lights indicate the operating status of the listed components Off or inactive On or active 1 More Cool 2 Less Cool 5 Heat Select Key Used to edit a parameter or save a changed parameter Raise and Lower Key Used to enter the setpoint temperature index t...

Page 39: ... and line The purge button is inactive when the TW is running WARNING Shut off the supply to cooling water inlet before purging Process Value Display The window displays the actual temperature of fluid entering the To Process line Audible Alarm Optional Setpoint Value Display The window displays the fluid temperature setpoint during normal operation Start Button Press and hold to begin normal oper...

Page 40: ...on in the lower right corner of the Process temperature display When the display is set to return temperature there is no orange indicating light in the lower right corner of the Process tempera ture display To toggle the Process temperature display from supply to return temperature press and release the Display Program button The display will return to the default Supply temperature automatically...

Page 41: ...equence or Process cool down sequence Coolant Pressure The Coolant Pressure In light will flash red if the inlet cooling water pressure drops below the set point of the low pressure safety switch If a low pressure condition occurs the unit will automatically stop and remain de energized until the cooling water pressure is above the cut in set point of the pressure switch The light is solid green i...

Page 42: ...or cool function assigned to the contact When enabled the controller does not perform any heat or cool functions and relies exclusively on the external contact closures for these functions however the unit maintains all warnings and safety functions From the factory the Remote Heat Cool feature is disabled See the Program Menu section for instructions on how to enable or disable this feature Do no...

Page 43: ...on in the process lines via the cooling valve 4 Press RUN The unit initiates a 30 second or as otherwise defined by user parameter venting sequence The Venting LED illuminates The pump starts after the venting cycle is over The Pump LED illuminates when the pump is running Normal operation begins The heater turns on if the actual temperature is below setpoint The cooling valve opens if the actual ...

Page 44: ...this hot fluid may result in steam formation and can cause personal injury and or property damage WARNING This equipment may contain fan blades or other sharp edges Make sure all fan guards and other protective shields are securely in place WARNING The exposed surfaces of motors heater tubes and other fluid circuit components can be very hot and can cause burns if touched with unprotected hands CA...

Page 45: ...pt for 7 hp and 10 hp units with the 300 F 149 C option that require lines and connectors rated for at least 175 psi 12 1 bar We recommend the cooling source supply and return lines are of metal composition black steel galvanized or copper Make sure that the cooling source is the appropriate temperature and pressure for your application In most cases the cooling source is between 40 F and 85 F 4 C...

Page 46: ...s of water can also encourage biological growth that can foul heat transfer surfaces To avoid the unwanted side effects associated with water cooling proper chemical treat ment and preventive maintenance is required for continuous plant productivity Unwanted Side Effects of Improper Water Quality Corrosion Scale Fouling Biological Contamination Cooling Water Chemistry Properties Electrical Conduct...

Page 47: ...the site using a test kit Dissolved Carbon Dioxide PPM TA x 2 6 3 pH 0 3 where TA Total Alkalinity PPM as CaCO3 CAUTION When your application requires the use of glycol use industrial grade glycol specifically designed for heat transfer systems and equipment Never use glycol designed for automotive applications Automotive glycols typically have additives engineered to benefit the materials and con...

Page 48: ...e When initiated the Auto Vent sequence opens the cooling valve for 30 seconds to allow air to escape This allows the majority of the air to escape from the system For further air purging the Auto Vent sequence energizes the pump for 30 seconds while the cooling valve is open to remove any remaining air from the system While in the vent sequence the Pump and Cool lights will flash Once the Auto Ve...

Page 49: ...int to 80 F 27 C and allow the Thermolator to cool itself to less than 100 F 38 C 2 Press STOP 3 Shut off the cooling water supply and relieve any pressure in the unit see pressure gauge by lifting the relief valve lever then drain the unit of all fluid The cooling water inlet hose can be removed to provide additional draining 4 Once the unit is cool remove the water hookups To shut down the unit ...

Page 50: ...Program button to scroll through the different adjustable parameters see Program Menu Items table 8 To change an item press the Display Program button until the item code dis plays in the Process display Pressing the Alarm Reset button and Display Program button at the same time will reverse the direction the Display Program button indexes through the menu items 9 Once the desired menu item code d...

Page 51: ...e set point Integral time Int 25 1 to 800 Low deviation alarm limit Lod 10 5 to 100 degrees below set point Low pressure bypass enabled pbE dIS Disabled DIS or Enabled EnA Panel Temperature Alarm PAe EnA Disabled DIS or Enabled EnA Panel Temperature Readout Pte Display only Proportional band bnd 20 1 to 300 Proportional band ratio Pbr 5 1 to 10 Pump run hours PrH 0 0 to 999 x100 Purge enabled opti...

Page 52: ...ss and hold the Start button then press the Stop button and release both buttons The Process Cool Down sequence begins if the process supply temperature is above 90 F 32 C Pump Running Hour Display The total accumulated pump running hours are stored for maintenance purposes See the Program Menu section to display the pump running hours Running hours are in units of hundreds so a display value of 1...

Page 53: ...temperature deviation 3 an alarm affecting the machine has occurred probe fault or pump fault 4 the controller has exceeded its over set point deviation 5 the controller has exceeded its below set point deviation Status Machine 1 20 42 Machine status in a 16 bit format as follows 0 controlling 1 an alarm is present 2 an alarm affecting the process has occurred high or low temperature deviation 3 a...

Page 54: ...9600 4028 MODBUS Identification R W Integer 4030 SPI Communications Address R W Integer 4038 PID OUT R 100 to 100 PID algorithm output 4039 MODBUS Command R W Integer 0 Do Nothing 1 Start 2 Stop 8002 Supply Fluid Temperature C R Floating Point Error Hi 9 9E05 Error Low 9 9E05 8004 Return Fluid Temperature C R Floating Point Error Hi 9 9E05 Error Low 9 9E05 8010 Low Temperature Deviation C R W Floa...

Page 55: ...g Point 8080 Remote Setpoint Limit Temperature C R Floating Point 8082 Remote Setpoint High Temperature Limit C R Floating Point Modbus Registers The following is a list of Modbus Registers that are remotely available Notes There is a limitation on the maximum Modbus block size of 40 for integers and 20 for floats Additional settings include Baud Set by parameter bAU 9600 baud by default Parity No...

Page 56: ...oling water pressure is higher than the air line cooling water may be injected into the air line 1 Press STOP to stop the Thermolator 2 Shut off the cooling water supply valve 3 Press MOLD PURGE Mold Purge to start purging The Purge LED lights The cooling valve is opened The time required to clear the process lines of fluid will vary according to the length of the process piping and the size of th...

Page 57: ...he upper green display shows the setpoint In the right hand column the various LEDs describe the status of the machine Mold Purge Rapid Cool Process Cool Down Control Power Autostart Signal Pump Heat Cool Coolant Pressure Temperature Limit Electrical Phase Error Heat Error Process Cool Down Rapid Cool Communications Remote Heat Cool Program Mode Mold Purge Flow GPM flash Continued Adjust setpoint ...

Page 58: ...4 22 I Operation ...

Page 59: ...he Pump Motor and Seal 1 2 to 2 Hp any frequency and 3 HP 60 Hz units 5 4 Reassembling the Pump Motor and Seal 1 2 to 2 Hp any frequency and 3 HP 60 Hz units 5 7 Removing the Pump Motor and Seal 3 Hp 50Hz and 5 to 10 Hp any frequency units 5 9 Reassembling Pump Motor and Seal 3 Hp 50Hz and 5 to 10 Hp any frequency units 5 11 Reset Pump Overload 5 12 Replacing the Controller Boards 5 13 ...

Page 60: ...o maintain the best performance we recommend the following maintenance schedule Daily or as often as necessary U U Check for leaks in cooling and process lines Before and during operation you should inspect the unit and all plumbing lines for leaks If a leak develops stop the Thermolator and repair it U U Keep the unit and the area around it clean Check for and remove lint dust or other obstructio...

Page 61: ... to less than 100 F 38 C To access the Thermolator enclosure 1 Remove the top panel 2 Remove each side panel by lifting straight up NOTE The side panels fit into slots at the bottom Note how they fit so that reassembly will be easy 3 Set the top panel and side panels out of the way for maintenance procedures Note that the right side and left side panels are unique and will only fit on the unit in ...

Page 62: ...e pump adapter to volute 3 Remove the casing O ring Inspect for damage or wear If in good condition set aside for re use If a new part is needed contact Conair Parts and request part number 267204 0160 02 Motor Motor Bolts Casing Casing O Ring Pump O Rings Impeller Locknut Impeller Casing Bolts Mechanical Seal Pipe Plug Motor Adapter Loc Tite Tools Required U U 9 16 inch wrench U U Flat blade scre...

Page 63: ...he flat sides of the motor shaft 6 Remove impeller lock nut using a 5 8 inch deep socket The lock nut is secured in place with a high perfor mance thread locker A significant amount of torque will be required to break it free Use the locking pliers at the other end of the shaft to prevent shaft rotation when removing the lock nut and impeller Standard clockwise thread is used 7 Unscrew the impelle...

Page 64: ...hip or scratch seal surfaces if it is to be re used Set seal half aside for re use if appropriate 9 Using a 9 16 inch wrench remove the four 4 casing bolts 10 Slide motor adapter off of motor shaft 11 Press stationary half of pump seal out of motor adapter being careful not to damage rubber diametral seal or rotating non rotating seal inter face surface Set seal half aside for re use if appro pria...

Page 65: ...amage rotating non rotating seal interface surface 2 Slide motor adapter as sembly on to motor shaft 3 Install and tighten the 4 bolts to 20 ft lbs 27 12 N m While tightening the bolts be careful to maintain the motor adapter perpendicular to the shaft 4 Slide the rotating portion of the shaft seal onto the shaft with the spring on the impeller side Tools Required U U 9 16 inch wrench U U Flat bla...

Page 66: ... and tighten to 12 ft lbs 16 27 N m Use a locking pair of pliers to grip the flat side of the shaft at the motor bell end Re install dust cap if removed during disassembly 8 Place pump to adapter o ring on motor adapter Locate the o ring as far up the adapter as possible such that it sits tight to the angle formed by the mounting flange 9 Locate the motor and motor adapter assembly on the pump vol...

Page 67: ...in place with a high performance thread locker A significant amount of torque will be required to break it free The impeller may be clamped on the smallest diameter round section behind the witness line of the casing interface only Do not damage the outside surface where the close clearance between the casing and impel ler exists Tools Required U U 9 16 inch wrench U U Flat blade screwdriver U U 9...

Page 68: ... be re used Set seal half aside for re use if appropriate 7 Slide shaft sleeve off of shaft 8 Remove 4 motor bolts using 9 16 inch wrench 9 Slide motor adapter off of motor shaft 10 Press stationary half of pump seal out of motor adapter being careful not to dam age rubber diametral seal or rotating non rotating seal interface surface Set seal half aside for re use if appropriate This area interfa...

Page 69: ...to the shaft 4 Slide the shaft sleeve over top of shaft 5 Slide the rotating portion of the shaft seal on to the shaft with the spring on the impeller side 6 Align the impeller and screw on to shaft 7 Place a small amount of Blue Loc Tite 271 on the impeller bolt thread 8 Install the impeller bolt and washer on the shaft tighten to 20 ft lbs 27 12 N m 9 Place pump to adapter o ring on motor adapte...

Page 70: ... the pump overload module attached to the pump motor starter 4 Disconnect the three power leads from the overload module to the pump motor Note the color placement of each lead and label as needed 5 Disconnect auxiliary wiring on the overload module 6 Remove the overload module Loosen the three screws that connect the over load module to the motor contactor Pull the overload module down to release...

Page 71: ...placing the main board and or any of the daughter cards please check care fully that all the jumpers and DIP switches on the new part are set exactly the same as the old part If the old part is not available for reference all factory jumper settings are shown on the electrical control prints 6 If replacing the main board insert all terminal strips Replace all daughter cards on plastic standoffs Ta...

Page 72: ...5 14 I Maintenance ...

Page 73: ...rms 6 5 Controller Control Fault Logic 6 14 Unit Faults 6 15 Unit Will Not Power Up 6 26 Troubleshooting 6 27 Replacing the Heater Contactor 6 29 Checking the RTD 6 30 Replacing the RTD 6 32 Repairing Cooling Valves 6 33 Disassembly of Alternate Direct Acting Solenoid Valves 6 34 Alternate Pilot Operated Solenoid Valves 6 35 Replacing Immersion Heaters 6 36 Removing the Pump 6 38 ...

Page 74: ...custom features or options not covered in this User Guide U U Verify that you have all instructional materials related to the Thermolator Additional details about troubleshooting and repairing specific components are found in these materials U U Check that you have manual for other equipment connected in the system Trouble shooting may require investigating other equipment attached to or connected...

Page 75: ...r than what is specified on the machine serial tag and data plate WARNING Electrical hazard Before performing maintenance or repairs on this product disconnect and lock out electri cal power sources to prevent injury from unexpected energization or start up A lockable device has been provided to isolate this product from potentially hazardous electricity WARNING Compressed air hazard If you use co...

Page 76: ...tarting up running steadily etc 4 Find the alarm or error code in the diagnostics tables in this section of the User Guide Causes are listed in the order of most likely to least likely problem 5 Determine and fix the cause of the alarm WARNING Always disconnect and lock out the main power source before opening the Thermolator or its electrical en closure Also disconnect air and water supply lines ...

Page 77: ... actuated X X Pump temporarily turns off X X Heater temporarily turns off X X Cooling valve continues to regulate This alarm will automatically reset when system pressure returns When it does the TCU will automatically resume nor mal operation Is fresh water turned on to the TCU Be sure to turn on the water sup ply before starting the TCU The pressure status can be observed on the COOLANT PRESSURE...

Page 78: ...LED X X Optional strobe sounds dry contacts actuated X X Pump turns off X X Heater turns off X X Cooling valve closes Once you have corrected the problem push the alarm si lence reset button to clear this alarm Then push the RUN button to restart the TCU Water pressure in your building is only marginally acceptable to run the TCU Any small fluctua tions can cause the TCU to cycle on and off repeat...

Page 79: ... flowing throughout the unit or between supply outlet and return inlet Verify that the unit is running and that the pump is working Check for closed or defective cooling or vent valves and plugged lines See Repairing Cooling Valves Check for external closed valve on the process fluid going to external equipment Check for a plugged pipe Did the cooling valve fail closed Check the cooling valves See...

Page 80: ...r Disassemble the cooling valve and check for particles blocking the valve seat Check the valve seat for excessive wear Replace as re quired using a valve repair kit See Repairing Cooling Valves Did a heater element fail or open With the unit powered down Check for loose connections on heater wir ing Check resistance between the phase legs on the output side of the heater contactor or SSR if prese...

Page 81: ...it or between the supply outlet and return inlet Verify that the unit is running and that the pump is working Check for closed or defective cooling or vent valves and plugged lines See Repairing Cooling Valves Check for external closed valve on the process fluid going to external equipment Check for a plugged pipe Did the cooling valve fail closed Check the cooling valve See Repairing Cooling Valv...

Page 82: ...mally This alarm can be reset by pushing the Alarm Silence Reset button once the temperature returns to an acceptable level Has water stopped flowing thought the unit or between the supply outlet and return inlet Verify that the unit is running and that the pump is working Check for closed or defective cooling or vent valves and plugged lines See Repairing Cooling Valves Check for external closed ...

Page 83: ...his alarm can be reset by pushing the Alarm Silence Reset button once the temperature returns to an acceptable level Is the cooling valve stuck open or leaking water Disassemble the cooling valve and check for particles blocking the valve seat Check the valve seat for excessive wear Replace as re quired using a valve repair kit See Repairing Cooling Valves Did a heater element fail or open With th...

Page 84: ...ontinues to run nor mally X X Heater continues to run normally X X Cooling valve continues to run normally This alarm can be reset by pushing the Alarm Silence Reset button once the temperature returns to an acceptable level Is the cooling valve stuck open or leaking water Disassemble the cooling valve and check for particles blocking the valve seat Check the valve seat for excessive wear Replace ...

Page 85: ...r has detected flow below the user configured low flow limit X X FLL is displayed in the setpoint display X X Pump continues to run nor mally X X Heater continues to run normally X X Cooling valve continues to run normally X X Alarm LED optional strobe sounder dry contacs are all not actuated This alarm will automatically reset once flow is above the low flow limit Is a valve closed in the process...

Page 86: ...The Set Point Temperature Display shows PRS and the Process Temperature Display shows ELo Yes Yes Yes Yes No Yes Return Probe Fault Hi The Set Point Temperature Display shows PRR and the Process Temperature Display shows EHi Yes Yes Yes Yes No Yes Return Probe Fault Lo The Set Point Temperature Display shows PRr and the Process Temperature Display shows ELo Yes Yes Yes Yes No Yes Brownout The Set ...

Page 87: ...personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED illuminated X X Optional strobe sounder dry contacts actuated X X Pump locks on X X Heater locks off X X Cooling valve locks open Power must be cycled to reset this fault Has water stopped flowing through the unit or between the supply outlet and return in...

Page 88: ...ing tem perature This is probably due to excessive temperature inside the electrical control enclosure WARNING Only qualified electri cal service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED illuminated X X Optional strobe sounder dry contacts actuated X X Pump operates normally X X Heater operates n...

Page 89: ...he reset button on the over load must be depressed to clear this fault See Resetting Pump Overload section Is enough restriction provided in the fluid circuit loop Install a flow reducing orifice or introduce some additional fit tings smaller diameter piping Is there mechanical binding due to a physical jam obstruction in the pump casing volute Remove the endcap from the mo tor and check that the ...

Page 90: ...king electrical current X X ALARM LED illuminated X X Optional strobe sounder dry contacts actuated X X Pump locks on X X Heater locks off although it is probably still active due to malfunction X X Cooling valve locks open Power must be cycled to reset this fault Have the electromechanical heat er contactor contacts welded shut and are preventing the contactor from mechanically shuttling to an op...

Page 91: ...ld examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED illuminated X X Optional strobe sounder dry contacts actuated X X Pump locks on X X Heater locks off X X Cooling valve locks open Power must be cycled to reset this fault Has the electromechanical heater contactor become jammed and is being prevented from me chanically ...

Page 92: ...running Note This fault can be selectively enabled disabled in the user menu under parameter brn WARNING Only qualified elec trical service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED illuminated X X Optional strobe sounder dry contacts actuated X X Pump turns off X X Heater turns off X X Cooling va...

Page 93: ...on direction TCU is factory wired for clock wise L1 L2 L3 phase rotation This fault is only present on TCU s that have the optional three phase monitor included WARNING Only qualified elec trical service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED illuminated X X Optional strobe sounder dry contacts...

Page 94: ...ycle to reset Fault Possible Cause Solution Pr5 EHi Supply Probe Fault Hi The To Process RTD is mal functioning or has a break in the wiring WARNING Only qualified elec trical service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED flashes in conjunction with SUPPLY LED X X Optional strobe sounder dry c...

Page 95: ...faults require a power cycle to reset Fault Possible Cause Solution Pr5 ELo Supply Probe Fault Low The To Process RTD is mal functioning or has a short circuit WARNING Only qualified elec trical service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED flashes in conjunction with SUPPLY LED X X Optional s...

Page 96: ...ycle to reset Fault Possible Cause Solution Prr EHi Return Probe Fault Hi The To Process RTD is mal functioning or has a break in the wiring WARNING Only qualified elec trical service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED flashes in conjunction with SUPPLY LED X X Optional strobe sounder dry c...

Page 97: ...ate Some faults require a power cycle to reset Fault Possible Cause Solution Prr ELo Return Probe Fault Low The To Process RTD is mal functioning or has a short circuit WARNING Only qualified elec trical service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current X X ALARM LED flashes in conjunction with RETURN LED X X O...

Page 98: ...temperature controller display Is power reaching the Thermolator Verify that the main power sup ply and any customer installed electrical disconnect or emer gency stop devices are in the ON position Verify correct electrical connec tions between the unit and the power supply Replace any dam aged wires or cables Is the correct voltage reaching the Thermolator Check the electrical requirements on th...

Page 99: ...ssary Failure of the microprocessor Replace controller Unable to heat properly Cooling valve is stuck in the open position Flush out the cooling valve by ad justing the Set Point up and down several times to open and close the cooling valve If this does not work stop the unit and turn off the electric power shut off the cooling source and take the valve apart for cleaning or replacement Leaking co...

Page 100: ...xchanger only on models with heat exchanger option Clean or replace heat exchanger High backpressure in the cooling water system Reduce backpressure Heater failure Unit not filled with water Fill unit with water Faulty heater Replace heater Plugged heater tube flow restric tion Clear obstruction Pressure relief valve leaks The combined pressure of the incoming cooling water pres sure and the unit ...

Page 101: ...ith the heater wires disconnected and find them continuously connected Or you have checked continuity across the power legs and find an open circuit even when the coil is energized To replace the heater contactor 1 Disconnect and lockout the main power 2 Open the electrical enclosure door Turn the screw on the front panel counterclockwise to open 3 Disconnect wires from the heater contactor Make s...

Page 102: ...er tank at the to pro cess outlet The other is installed in the mixing tank or heat exchange near the from process outlet Sensor error codes Er iI displayed by the temperature controller may indicate RTD failure To check a RTD after a sensor error 1 Disconnect and lockout the main power 2 Open the electrical enclosure door Turn the screw on the front panel counterclock wise to open 3 Remove RTD wi...

Page 103: ...5 123 7 123 9 124 1 124 3 124 5 124 7 124 9 125 2 60 0 150 125 4 125 6 125 8 126 0 126 2 126 4 126 6 126 9 127 1 127 3 65 6 160 127 5 127 7 127 9 128 1 128 3 128 6 128 8 129 0 129 2 129 4 71 1 170 129 6 129 8 130 0 130 3 130 5 130 7 130 9 131 1 131 3 131 5 76 7 180 131 7 132 0 132 2 132 4 132 6 132 8 133 0 133 2 133 4 133 6 82 2 190 133 9 134 1 134 3 134 5 134 7 134 9 135 1 135 3 135 5 135 8 87 8 ...

Page 104: ... RTD at least 1 inch into the tank Tighten the compression nut Thread the leads through the raceway leading to the electrical enclo sure 6 Re secure RTD wires to the various wire mounts to keep the wire from contacting the heater housing pump casing or motor housing Wire the RTD wires to secure them within the electrical cabinet 7 Trim extra wire off if possible Strip and attach RTD leads to the t...

Page 105: ...g water out 4 Disconnect and lockout main power 5 Remove the valve from the cooling water out line 6 Disassemble the valve See exploded views on next page 7 Inspect and clean or repair the valve body assembly Remove foreign par ticles and replace damaged parts as necessary 8 Reassemble the valve and other components Reassemble in reverse order Seal all pipe fittings with pipe sealant Check that al...

Page 106: ...al ly in the status that there are not gaps between the coil assembly and body Tighten the screws in the order of 1 2 3 4 1 2 3 4 Proper Tightening Torque 267201 01 267201 02 0 37 lbf ft 0 5 N m All others 0 52 lbf ft 0 7 N m 4 After tightening the screws make sure that there are no gaps between the coil and body 5 After the disassembly and assembly have been completed make sure that no leak occur...

Page 107: ...bleshooting I 6 35 6 Tr o u b le sh ooti ng Alternate Pilot Operated Solenoid Valves Clip Name Plate Solenoid Coil Assembly NOTE Within the valve body and coil assembly there are no user serviceable parts 0 ...

Page 108: ...elled as 3T1 3T2 3T3 if dual fed or 48kw units Record the position of bus links jumpers and feed wires so they can be replaced in exactly the same manner on the replacement heater Then unscrew the nuts on the cable connectors and remove the wires 5 Shut off the cooling water in 6 Drain the Thermolator using the Pressure Relief Valve located at the rear of the unit 7 Remove the four bolts that hold...

Page 109: ...heater tank Remove any rust or solids that may have built up before inserting the heater elements 10 Replace the heater gasket if it is worn or cracked 11 Reverse these steps to install the new heater element and reassemble the unit Heater cap Immersion Heater Heater gasket Contact Conair Parts and Service Phone 800 458 1960 From outside of the United States Call 814 437 6861 ...

Page 110: ... holding the pump to the pump casing The bolt in the rear will require a 9 16 inch socket wrench 6 Remove the center brace that runs from the top rear to the front of the Thermolator 7 Lift the pump assembly straight up to remove The pump can now be replaced or disassembled for repair The center brace detail needs to be removed on selection pumps removal 8 Reverse the steps to reassemble the unit ...

Page 111: ...rly rate with a one day minimum plus expenses Before You Call If you do have a problem please complete the following checklist before calling Conair U U Make sure you have all model control type from the serial tag and parts list numbers for your particular equipment Service personnel will need this information to assist you U U Make sure power is supplied to the equipment U U Make sure that all c...

Page 112: ...ptions Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication improper installation poor maintenance practices or improper operation Replace the original equipment with other Conair equipment that will meet original performance claims at no extra ...

Page 113: ...al The main driver for the Thermolator control loop is the proportional response Propor tional logic is very simple it selects a heating or cooling level strength based on how close the process temperature is to the setpoint The proportional parameter defines a band over what range of degrees the temperature controller will taper off its heating or cooling Heating Cooling will be applied at 100 if...

Page 114: ...ding floating valve option Like integral logic it is aware of the passage of time it looks forward into the future and anticipates if the machine will be overshooting the setpoint at some point in the future based on current trends Derivative action is disabled whenever the Thermolator is far further than twice the proportional band from the setpoint A larger number will produce a more aggressive ...

Page 115: ...the system begins to oscillate around the setpoint you have gone too far 8 Cool down your system and repeat the experiment so you can truly observe the process temperature approaching setpoint You will probably observe the temperature overshooting the setpoint If overshoot is acceptable for your process there is no reason to continue tuning If you would like to eliminate overshoot in exchange for ...

Page 116: ...nauthorized changes Access to all user configurable parameters can be limited by selecting a three digit passcode between 0 and 500 While the TW S and TW P ships with the factory default 0 as the passcode we recom mend selecting your own unique passcode to protect your machine setup and application To change the security passcode 1 Stop the TCU or ensure that you are on the home screen by pressing...

Page 117: ...ss Cooling Water In Cooling Water Out Cooling Valve Mixing Tank Pump From Process RTD Low Pressure Switch From Process Pressure Gauge To Process Pressure Gauge Relief Valve Bypass De aeration or Optional 2nd Heater To Process RTD TW S Direct Injection Continued ...

Page 118: ...C 2 I Appendix Plumbing Diagram Closed Circuit Separate Source In this configuration process and cooling fluids do not mix Continued Continued TW P Closed Circuit Separate Source ...

Page 119: ...rce In this configuration process and cooling fluids mix only at filling Fill line is used for both pressurization and expansion of process fluid causes limited inter action of process and cooling water Continued TW S Closed Circuit Optional From Process RTD ...

Page 120: ...lled Pump Performance Reference Configura on 12 kW 250 F Max 60 Hz 0 10 20 30 40 50 60 70 80 90 100 0 20 40 60 80 100 120 140 160 Volumetric Water Flow gpm Pressure Rise Across Unit psid 3 4 hp 1 hp 2 hp 3 hp 5 hp 7 1 2 hp 10 hp 3 4 hp 1 hp 2 hp 3 hp 5 hp 7 1 2 hp 10 hp Continued ...

Page 121: ...losed Circuit with Standard Heat Exchanger Reference Configura on 12 kW 250 F Max 60 Hz 0 10 20 30 40 50 60 70 80 90 100 0 20 40 60 80 100 120 140 Volumetric Water Flow gpm Pressure Rise Across Unit psid 3 4 hp 1 hp 2 hp 3 hp 5 hp 7 1 2 hp 10 hp 3 4 hp 1 hp 2 hp 3 hp 5 hp 7 1 2 hp 10 hp Continued Continued ...

Page 122: ...Closed Circuit with High Performance Heat Exchanger Reference Configura on 12 kW 250 F Max 60 Hz 0 10 20 30 40 50 60 70 80 90 100 0 20 40 60 80 100 120 Volumetric Water Flow gpm Pressure Rise Across Unit psid 3 4 hp 1 hp 2 hp 3 hp 5 hp 7 1 2 hp 10 hp 3 4 hp 1 hp 2 hp 3 hp 5 hp 7 1 2 hp 10 hp Continued ...

Page 123: ...X 2672030000A5 3 208 230 460 60 X 2672030000A6 5 208 230 460 60 X 2672030000A7 7 5 208 230 460 60 X 2672030000A8 10 208 230 460 60 X VOLUTE CASING 2672030000E4 3 4 208 230 460 60 X 2672030000E4 1 208 230 460 60 X 2672030000E5 2 208 230 460 60 X 2672030000E5 3 208 230 460 60 X 2672030000E6 5 208 230 460 60 X 2672030000E6 7 5 208 230 460 60 X 2672030000E6 10 208 230 460 60 X MOTOR ADAPTERS 267203000...

Page 124: ...10 2 208 230 460 60 X 2672030000G11 3 208 230 460 60 X 2672030000G12 5 208 230 460 60 X 2672030000G13 7 5 208 230 460 60 X 2672030000G14 10 208 230 460 60 X SEAL KITS 267203SK0101 3 4 267203SK0102 3 4 267203SK0101 1 267203SK0102 1 267203SK0101 2 267203SK0102 2 267203SK0101 3 267203SK0102 3 267203SK0201 5 267203SK0202 5 267203SK0201 7 5 267203SK0202 7 5 267203SK0201 10 267203SK0202 10 Continued ...

Page 125: ...ture Setpoint Input 11kΩ internal controller impedance 50Ω internal controller impedance NOTE Voltage or loop current source must be supplied by the external interface Process Temperature Retransmit Output 1kΩ minimum external impedance 500Ω maximum external impedance NOTE Voltage or loop current is self generated by the TCU s temperature controller Terminal Wiring Jumpers 0 10VDC 4 20mA Remote Te...

Page 126: ...ment 4 20mA Placement 0 10V JMP1 Pins 2 4 Pins 1 2 500Ω Maximum input imped ance Terminate analog output signal wire directly on J12 daughter board connector J1 NOTE Voltage signal is self generated by temp controller but is not ground isolated Customer s interface must be isolated from ground or ground loop damage will result NOTE Current signal is self generated by temp controller but is not gro...

Page 127: ...our TCU will come pre configured to accept a remote setpoint This means that you will NOT be able to select a setpoint directly from the temperature controller without changing the default parameters Addi tionally the TCU comes from the factory set to 0 20mA covering the entire range of 10 F to 260 F Process Value Related Parameters U38 Communications type Cot rEt OFF Retransmit rEt ModBus RTU bUS...

Page 128: ...E 4 I Appendix ...

Page 129: ...60 60 60 60 3 kW A 65 65 65 60 60 60 60 6 kW B 65 65 65 60 60 60 60 9 kW C 65 65 65 60 60 60 60 12 kW D 65 65 65 60 60 60 60 18 kW E 65 65 65 60 60 60 60 24 kW F 60 60 60 60 60 60 60 36 kW G N A 75 75 75 60 60 60 48 kW H N A 75 75 75 60 60 60 For 300 F 149 C 48 kW Direct Injection units the minimum pressure in the suction tank for the 12 kW heater to operate is 80 psig Minimum System Pressure Requ...

Page 130: ...5 65 65 60 60 60 18 kW E 65 65 65 65 60 60 60 24 kW F 65 60 60 60 60 60 60 36 kW G N A N A N A N A 60 60 60 48 kW H N A 75 75 75 60 60 60 Minimum System Pressure Required for System Operation in psig for 50 Hz Input Power Digit 7 of Part is E Heater Capacity Digit 7 of Part Pump Power Digit 6 of Part hp hp 1 hp 2 hp 3 hp 5 hp 7 hp Description Description Digit 7 Value C D E H J K L Digit 6 Value 0...

Page 131: ...ping and configuration the mold purge should always be added to the existing piping attached to the unit NOTE Solenoid valves shown are for reference only Actual valves supplied could look different 3 Starting with the part in Detail A closest to the heater tank add sealant to the threads and attach components to the tank or the end of the To Process line plumbing at tached to the unit If a To Pro...

Page 132: ...h solenoid valve to the duplex connector on the back of the mechanical enclosure 8 Using anti short bushings on each end of the conduit pieces run the wires of the solenoid valves through the separate pieces of flex conduit the duplex connector and elbow the mechanical enclosure the hole towards the bottom of the electrical enclosure back panel labeled in Detail B and into the electrical enclosure...

Page 133: ...shing in the hole in the bottom right corner on the back of the mechanical enclosure and labeled in Detail A 18 Run the cables through the hole with the bushing just attached through the hole in the back of the electrical enclosure labeled in Detail B and into the electrical enclosure 19 Wire the electrical components according to the mold purge option in the control schematic shown below Premium ...

Page 134: ...G 4 I Appendix ...

Page 135: ...y contacts reduce the process flow below the designated alarm threshold to test if they were set up properly Flowmeter installation instruction sheet PRH021 0915 1 Remove the plumbing connection from the unit to the process 2 Add sealant to threads and attach flow meter and fittings to the unit according to the figure below The flow direction is indicated on the valve body Make sure the meter is i...

Page 136: ...H 2 I Appendix ...

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